大型铝合金曲面零件电磁渐进成形线圈结构优化设计  

Structure optimization design of coil on electromagnetic incremental forming of large aluminum alloy curved surface parts

作　　者：汪志强[1] 黄亮[1] 李建军[1] 王森博 刘贤龙[1] 

机构地区：[1]华中科技大学材料科学与工程学院材料成形与模具技术国家重点实验室,武汉430074

出　　处：《塑性工程学报》2015年第6期71-77,共7页Journal of Plasticity Engineering

基　　金：国家自然科学基金资助项目(51575206);国家重点基础研究发展计划资助项目(2011CB012802)

摘　　要：针对大型铝合金曲面零件电磁渐进成形工艺中板料不均匀变形的问题,基于ANSYS多物理场模块建立电磁场-结构场耦合模型,对成形过程进行数值模拟分析,研究电磁成形线圈结构参数对板料变形行为的影响,包括:线圈层数、线圈匝间距、线圈层间距、导线截面积和导线截面形状。研究表明,线圈层数增加,板料变形均匀性降低,而板料的变形量增大,多层线圈有利于提高线圈的强度和使用寿命;线圈匝间距与导线的宽度越接近,板料均匀变形效果越好;矩形导线截面的线圈相对圆形导线截面的线圈使板料变形更加均匀;线圈层间距和导线截面积对板料均匀变形影响不大,但是合理的结构参数可以提高线圈强度。提出了一种非等间距线圈结构,非等间距线圈产生的电磁场和电磁力是不均匀的,在板料半径1/3处受到的成形驱动力较大,而这种不均匀的变形力,进一步改善了电磁成形中板料的变形不均匀性,电磁成形平板线圈能与变形后的板料较好的贴合,使大型铝合金曲面零件电磁渐进成形能通过多次放电连续均匀塑性变形。通过实验验证了线圈结构优化设计的可靠性,实验结果与模拟结果基本一致,误差在12%以内。Aiming at the inhomogeneous deformation of aluminum alloy curved surface part during the electromagnetic incremental forming process,the coupled numerical model of electromagnetic forming was build based on multi-physics tools from ANSYS,the forming process was simulated,and the influence of structure parameters of coil on plastic behavior of sheet metal was researched,including the layers of the coil,the spacing between the turns,the spacing between the layers,the sectional area of the wire and the cross-section shape of the wire.The results show that,the homogeneity of the sheet metal deformation reduces,the deformation of the sheet metal increases and the strength and the working life of the coil increases with the increase of the layers.The homogeneity of the sheet metal deformation is relatively good when the spacing between the turns is equal to the width of the wire.Compared with the round section of the coil,the homogeneity of the sheet metal deformation is good with square cross-section wire.The influence of the spacing between the layers and the sectional area of the wire on the homogeneity of the sheet metal deformation is not evident,while reasonable parameters is benefit to increasing the strength of the coil.After that,the structure of a non-equidistance coil was brought out.The electromagnetic field and the electromagnetic force is asymmetrical.The driving force reaches maximum on the location of 1/3of the radius,which improves the homogeneity of the sheet metal deformation.Thus,the electromagnetic forming flat coil can be pressed close to sheet metal and the multiple discharge electromagnetic incremental forming process of aluminum alloy curved surface part can keep on continuously.Finally,the reliability of the structure of the coil is verified via the experiments.The results of experiments coincide to the numerical analysis and the error is no more than 12 percent.

关 键 词：大型铝合金曲面零件 电磁渐进成形 线圈结构优化设计 

分 类 号：TG386[金属学及工艺—金属压力加工]